70000457_a4-p________1.0_en

INSTRUCTION MANUAL

ROTARY KILN

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Alignment of supporting roller bearings and supporting rollers. Support type SA ERECTION In the text, reference is made to: Ref. 1

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Ref. 2

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Ref. 3 Ref. 4

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Rotary kiln General kiln instruction manual Erection, operation and maintenance Rotary kiln plant, (dry process) Safety regulations General safety regulations at sites of erection Rotary kiln Alignment of self-adjusting bedplate Erection

*) See note ”Instruction manual references” in section 1.

VIGERSLEV ALLÉ 77 - 2500 VALBY - DENMARK ‹ 2040 AVENUE C - PA 18017-2188 BETHLEHEM – USA ‹ CAPITAL TOWERS 180. KODAMBAKKAM HIGH ROAD, NUNGAMBAKKAM,- CHENNAI 600 034 - INDIA

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CONTENTS: PAGE: 1. General notes .................................................................................. 4 2. Construction and operating principle ................................................ 5 3. Installation ....................................................................................... 6 3.1 Alignment of supporting bearings and supporting roller bearings................................... 6 3.2 Installation of supporting roller ........................................................................................ 6 3.3 Positioning of the supporting bearings relative to kiln axis.............................................. 7 3.4 Measuring tools............................................................................................................... 7 3.4.1 Theodolite .................................................................................................................... 7 3.4.2 Measuring tools............................................................................................................ 7 3.4.2.1 Measuring with tools ................................................................................................. 8 3.5 Marking the zero position of the bearings ..................................................................... 10

4. Operation ...................................................................................... 11 5. Maintenance .................................................................................. 11 6. Key to Appendices ......................................................................... 12

Edited by: Approved by:

KelH KelH

Pages: 21

Translated by: MGN code:

5A10

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APPENDICES: App. 1. App. 2. App. 3. App. 4. App. 5.

Sketch of bearing shell.............................................................................................. 13 Erection tools ............................................................................................................ 15 SA support ................................................................................................................ 17 SA support ................................................................................................................ 19 Marking plates........................................................................................................... 21

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NOTE! The present instruction manual is concerned with the situations which, according to the experience of FLS, are the most likely to occur. An exhaustive enumeration of all conceivable situations which may occur in connection with the installation, operation and maintenance of the kiln cannot be provided. Consequently, if a situation should arise, the occurrence of which is not foreseen in the instruction manual, and which the operator is/or feels unable to handle, we would recommend that FLS is contacted without undue delay for advice on appropriate action. 1.

GENERAL NOTES This instruction manual describes how to perform the final alignment of supporting roller bearings and supporting rollers on a self-adjusting support, type SA. It is a foregone conclusion that the bedplate has been aligned and embedded exactly as specified in relevant instruction manuals, see ref. 1. References to instruction manuals In the text of this instruction manual, reference is made to an instruction manual reference No. where this is deemed to be relevant. The titles of all instruction manuals referred to are listed on the front page of this instruction manual, with indication of the number referred to. Reference to other instruction manual numbers is done via the ”General kiln instruction manual”, ref. 1 in which relevant instruction manual numbers can be identified on the basis of the title of the relevant manual. REQUIREMENT: Bearings to be used exclusively for the aforementioned purpose! MANDATORY! The directions outlined in instruction No. ref. 2 "General safety regulations at erection site" must be strictly observed at the site of erection. This instruction manual must be scrutinized by the client, the erection contractor and FLS representatives before erection work is started.

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MANDATORY!: The erection/maintenance activities described in the following sections must only be carried out by skilled machine specialists or subject to the supervision of such specialists.

MANDATORY!: In connection with arc welding and when operations involving blowtorching with gouge are carried out, the return cable must always be attached to the object subjected to welding, as close as possible to the area of welding. The return cable must never be attached in a way which will cause the return current to be passed through parts not connected to the object being welded, for example: moving parts, bearings, electrical installations or any other parts. A return current through a bearing may give rise to welding scars which will cause severe damage to bearing. A return current through electrical installations may cause serious damage to protective earth lines (extremely hazardous condition!) or electronic equipment. Where ERECTION CHECK is specifically called for in the erection manual, this means that the FLS erection supervisor must inspect and approve the parts mounted before permission to proceed with the erection work can be given.

2.

CONSTRUCTION AND OPERATING PRINCIPLE See instruction manual for supporting roller bearings and bedplate.

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3.

INSTALLATION

3.1

Alignment of supporting roller bearings and supporting rollers Final positioning of supporting roller bearings in the longitudinal direction of kiln following the fine alignment, embedment and finish-mounting of the complete bedplate, inclusive of tilting beams. NOTE!: In connection with the alignment of bearings and supporting rollers, it is very important to protect the open bearings against exposure to contamination. The period during which the bearings are unprotected must be reduced to an absolute minimum. The supporting rollers must be individually aligned and it is the responsibility of the erection supervisor to make sure that the final installation of bearings will take place immediately after the alignment work has been completed. If the operation is interrupted, for example at the end of the working day, it is essential to ensure that the bearings are covered to extent necessary. It would be advisable to close the oil pockets along the journal, using a length of duct tape. Just before the top part of the bearing is remounted, the bearing must be blown clean, and the tape ducts must be removed. During the installation procedure, the inspection covers should be effectively secured to prevent them from being opened by any unauthorized persons.

3.2

Installation of supporting roller See Appendix 4. The position of the bearings must be adjusted in the longitudinal direction of kiln after the supporting roller has been mounted in the bearings, but not until it has been eased off completely. Bearings to be positioned so that there will be a clearance ranging from 5 to 8 mm between the bearing shell and the thrust ring of the supporting roller shaft at the inlet side when the thrust ring is lying true against the bearing shell at the outlet side. See Appendix 4.

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If the second supporting roller has been aligned, endeavours are needed to ensure that the two supporting rollers, to maximum practicable extent, are flush in the longitudinal direction of the kiln. The next step involves welding-on of the guide blocks (21) on the bearing beams along the outer side of the bearings to prevent displacement of the bearings when subjected to the axial loads which are transmitted to the bearings via the thrust rings of the supporting roller shaft. The blocks are shown in Appendix 5. 3.3

Positioning of supporting roller bearings relative to kiln axis Check that the centre marking of the bedplate (the frame structure) consistently matches the markings of the other bedplates (the projection of kiln in the horizontal plane). See instruction manual ref. 4. For measuring tools, see section 3.4. If no irregularities are ascertained, the supporting roller can be moved to its final position relative the centreline (kiln axis). The main priority is to attain parallelism between the supporting roller and kiln axis, and, therefore, it will be possible to position each supporting roller separately, thereby minimizing the period of time during which the individual supporting roller bearing is open and unprotected.

3.4

Method of measuring Different methods of measuring can be used. The two methods described in this manual have a record of success.

3.4.1

Theodolite A theodolite is mounted in the centreline of the kiln on one of the foundations. From the theodolite, the distance is measured from the centreline to each bearing in the centreline of the kiln. The final C-measurements are indicated on the position drawing of kiln. A measuring ruler is laid up against the supporting roller shaft and a readout of the distance C-r can be obtained through the telescope of the theodolite, see Appendix 3. After the measurements have been taken, it is essential to check the position of the theodolite itself and to check the direction in relation to the kiln centreline.

3.4.2

Measuring tools See Appendix 2.

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Make a set of measuring tools consisting of 1 measuring rod (18) and 2 measuring angles (14) as illustrated in Appendix 2. Only one set of measuring tools is used for the entire kiln. The measuring rod (18) must be straight, and its length must be determined in relation to the largest c-measurement on the position drawing. To prevent the rod from being turned when measuring is done, a short piece of flat iron (19) is welded to the rod as illustrated in Appendix 2, fig. 4. The measurement ”C-r” must be indicated on the measuring rod for each support, for example by scribing thin lines using white lacquer paint. The lines must be thin and sharp in order to ensure precision of measurements. See Appendix 2, fig. 5. Make the measuring angles (14) of sectional iron in a dimension which will provide the necesssary degree of rigidity, as illustrated in Appendix 2, fig. 1. By welding on a thin plate (15) and on the basis of marking, the centre of which must indicate the front edge of the measuring angle (Fig. 3), the angle can advantageously be used also for mounting the frame structures on the foundations. In the vertical legs of the angles a number of holes (16) must be drilled; the distance of these holes from the foot of the angle must be equal to the roller centre height J (see position drawing) + thickness of the plate (19), which is indicated here to be 6 mm. The number of holes depends on the specific number of different bearing sizes (heights J) which exist for the kiln in question. 3.4.2.1

Measuring with tools One of the adjusting units (25) used for kiln erection can advantageously be used; it should be tack-welded to the bedplate so that the measuring angle can be moved to different positions when alignment of the different bearings is being carried out, see Appendix 3. Fix the angles on the frame so that they lie true against a piano wire or a straightedge which in turn must be lying true against the centre marking blocks (22). See Appendix 4. When fixing the angles, the inclinometer (17) should be used to check that the angles are identically positioned. If necessary, thin shims must be inserted under the end of the foot of one angle.

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Effective clamping of the measuring angles must be ensured to prevent them from coming out of alignment, even when subjected to moderate impacts. Place the measuring angle in the angle, and perform measurements directly in relation to the bearing journal. The mark for the support involved must be flush with the front edge of the measuring angle when the distance is correct. See Appendix 2, fig. 2. When the distance at both bearing journals is correct, the supporting roller will be correctly positioned relative to the centreline (kiln axis). Fix the bearings to the bearing beam, and make sure that the adjusting screws (20) exert a moderate pressure against the base of bearing.

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Marking the zero position of the bearings On completion of check measurements, and any necessary corrections, the zero position of the bearings on the bearing beams must be marked off by means of clearly visible chisel cuts or heavily inscribed lines immediately opposite each other in bearing housing and bearing beam, possibly in guide block (21), as illustrated in Appendix 5. It is of paramount importance that this marking is done very carefully, and as soon as the position of roller is found to be correct this will be the only visual way of checking that the bearings are correctly positioned during the ensuing erection process. The supplied brass plates (angles) (23) must not be mounted until at the final stages of kiln erection; otherwise, they are prone to disappear during the process. This factor further emphasizes the importance of the chisel cut markings. The brass plates must be mounted so that their edges are flush and positioned exactly on-line with the marks on the guide block. The ”pointed” end of the plates must be facing the adjusting screw (20). Threaded holes must be drilled in the bearing housing as well as the guide block. After the plates have been fixed by means of screws and the screw heads have been secured by means of chisel cuts, the two ”pointed” ends must be very carefully trimmed (using a smooth-cut file) so that they form a coinciding face (24).

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OPERATION Not described in this instruction manual.

5.

MAINTENANCE Not described in this instruction manual.

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APPENDICES 01. Support plate for rocker bearing 02. Rocker bearing 03. Tilting beam 04. Elastomer bearing 05. Bearing beam 06. Supporting roller 07. Adjusting screw 08. Central frame 09. Hinged bearing 10. Supporting bracket with elastomer bearing 11. Bearing 12. Fondation bolts 13. Foundation 14. Measuring angle 15. Thin sheet with central marking 16. Hole for measuring rod 17. Inclinometer 18. Measuring rod 19. Flat iron 20. Adjusting screw 21. Guide block 22. Central marking block 23. Brass plate 24. Faces which must be flush 25. Adjusting unit

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Appendix 1. Sketch of bearing shell

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14. Measuring angle 15. Thin sheet with central marking 16. Hole for measuring rod 17. Inclinometer 18. Measuring rod 19. Flat iron

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Appendix 2. Erection tools

15

16

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25. Adjusting unit

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Appendix 3. SA support

17

18

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Appendix 4. SA support

19

20

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11. Bearing 20. Adjusting screw 21. Guide block 23. Brass plate 24. Faces which must be flush

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Appendix 5. Marking plates ---o0o---

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